Vacuum insulated structure tubular cabinet construction
A refrigerator includes a vacuum insulated cabinet structure having side walls that are formed from a tube that has been folded/deformed into a structure having an “O” shape with vertically enlarged front and rear openings. The interior of the tube may be filled with silica powder or other filler, and a vacuum is formed within the tube. An insulated rear panel may be utilized to close off the rear opening of the vacuum insulated cabinet structure.
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The present application is a divisional of U.S. patent application Ser. No. 13/836,143 filed on Mar. 15, 2013, now U.S. Pat. No. 9,071,907, entitled “VACUUM INSULATED STRUCTURE TUBULAR CABINET CONSTRUCTION,” which claims priority to U.S. Provisional Patent Application No. 61/618,914 filed on Apr. 2, 2012, entitled “ENERGY EFFICIENT HOME APPLIANCES.”
The present application is also related to U.S. patent application Ser. No. 13/833,635, filed Mar. 15, 2013, entitled “A METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS,” now abandoned; and U.S. patent application Ser. No. 13/836,669, filed Mar. 15, 2013, entitled “FOLDED VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 9,140,481; and U.S. patent application Ser. No. 13/835,449, filed Mar. 15, 2013, entitled “A VACUUM PANEL CABINET STRUCTURE FOR A REFRIGERATOR,” now U.S. Pat. No. 8,944,541; and U.S. patent application Ser. No. 13/832,246, filed Mar. 15, 2013, entitled “DUAL COOLING SYSTEMS TO MINIMIZE OFF-CYCLE MIGRATION LOSS IN REFRIGERATORS WITH A VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 9,182,158; and U.S. patent application Ser. No. 13/833,696, filed Mar. 15, 2013, entitled “VACUUM INSULATED DOOR STRUCTURE AND METHOD FOR THE CREATION THEREOF,” now U.S. Pat. No. 9,038,403; and U.S. patent application Ser. No. 13/837,659, filed Mar. 15, 2013, entitled “FOLDED VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 8,986,483; and U.S. patent application Ser. No. 13/833,635, filed Mar. 15, 2013, entitled “METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS,” now abandoned, all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTIONVarious types of insulated cabinet structures have been developed for refrigerators, freezers and the like. Known refrigerator cabinet structures may include inner and outer walls with urethane foam or other insulating material disposed between the inner and outer walls.
SUMMARY OF THE INVENTIONOne aspect of the present invention is a method of fabricating a vacuum insulated refrigerator housing. The method includes forming an elongated tube having opposite open ends defining a link therebetween. The tube may be formed from a metal material, or the tube may comprise multiple layers of polymer material, wherein one of the layers is substantially impermeable to gasses such as nitrogen, oxygen and water vapor. The elongated tube has a substantially uniform cross-sectional shape along the length of the tube, and the tube defines generally planar first and second oppositely facing primary outer surfaces. The tube further includes first and second end surfaces extending between the first and second primary outer surfaces. The method further includes forming the tube along at least four fold lines to form at least four corners, whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another. The method further includes sealing the opposite ends of the elongated tube to form an air-tight insulating space within the tube. The opposite ends of the tubes are connected to one another to form a refrigerator housing structure that is generally “O” shaped with horizontally spaced apart, generally vertical side walls and vertically spaced apart generally horizontal upper and lower side walls forming four corners. The refrigerator housing structure defines an internal space having enlarged front and rear openings. The method further includes forming a vacuum in the insulating space within the tube, and attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
Another aspect of the present invention is a method of forming a vacuum insulated refrigerator housing structure. The method includes forming an elongated tube having opposite ends. The opposite ends are sealed to form an air-tight insulating space within the tube. The method further includes forming a vacuum in the air-tight insulating space, and positioning the opposite ends of the tube adjacent to one another by deforming the tube. The opposite ends are connected together to form a refrigerator housing structure that is generally “O” shaped with spaced apart upright side walls, and spaced apart upper and lower side walls extending between the upright side walls. The refrigerator housing structure defines an internal space and enlarged front and rear openings.
Another aspect of the present invention is a vacuum insulated refrigerator housing structure including a pair of horizontally spaced apart upright side walls defining upper and lower end portions. The vacuum insulated refrigerator housing structure also includes an upper side wall having opposite ends connected to the upper end portions of the upright side walls, and a lower side wall having opposite ends connected to the lower end portions of the upright side walls. The upright side walls and the upper and lower side walls comprise a one-piece integral tubular structure forming air-tight insulating space within the upright side walls and the upper and lower side walls. The air-tight insulating space is evacuated and thus forms a vacuum insulated structure.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
With reference to
With further reference to
The tubular primary structure 16 is made from an elongated tube 44 (
With further reference to
After a sufficient length of tubing 44 is extruded (
With further reference to
After formation of indentations 70 and/or 72 and grooves 74 and/or 76, the tube 44 is bent utilizing forming tools 82A-82D to form corners 46A, 46B, 48A and 48B as shown in
With reference to
With further reference to
As discussed above, the tubular primary structure 16 includes enlarged front and rear openings 22 and 24. The openings 22 and 24 generally define a rectangular perimeter 20, and the tubular primary structure 16 has a generally rectangular perimeter 18 in an elevational view (e.g.
With further reference to
Referring again to
The filler material 54 may also be added after the tube 44 is bent into an O-shape (e.g.
Claims
1. A free-standing vacuum insulated refrigerator housing structure comprising:
- a pair of horizontally spaced apart upright primary side walls, each primary side wall defining upper and lower end portions and spaced apart inner and outer side walls and spaced apart front and rear edge walls extending transversely between the inner and outer side walls such that each primary upright side wall forms a dosed tubular section defining a vertically extending interior space;
- a horizontally extending upper side wall having an interior space and including opposite ends connected to the upper end portions of the primary upright side walls;
- a horizontally extending lower side wall having an interior space and including opposite ends connected to the lower end portions of the primary upright side walls;
- porous insulating material disposed in the interior spaces of the primary upright side walls, the upper side wall, and the lower side wall;
- wherein the primary upright side walls and the upper and lower side walls comprise a one piece integral tubular structure defining an insulated interior space, wherein the one piece integral tubular structure has a front perimeter extending around a front opening that provides access to the insulated interior space and wherein the interior spaces of the primary side walls, the upper side wall, and the lower side wall have a vacuum formed therein; and
- at least one door movably connected to the one piece integral tubular structure whereby the at least one door at least partially closes off the front opening when the at least one door is in a closed position, and wherein the at least one door provides access to the insulated interior space through the front opening when the at least one door is in an open position.
2. The free-standing vacuum insulated refrigerator housing structure of claim 1, wherein:
- the one piece integral tubular structure comprises metal.
3. The free-standing vacuum insulated refrigerator housing structure of claim 2, wherein:
- the one piece integral tubular structure comprises low carbon steel.
4. The free-standing vacuum insulated refrigerator housing structure of claim 2, wherein:
- the one piece integral tubular structure comprises aluminum.
5. The free-standing vacuum insulated refrigerator housing structure of claim 1, wherein:
- the one piece integral tubular structure comprises a polymer material.
6. The free-standing vacuum insulated refrigerator housing structure of claim 5, wherein:
- the one piece integral tubular structure comprises a thermoplastic polymer material that is co-extruded with a layer of impermeable polymer material.
7. A free-standing vacuum insulated refrigerator housing structure comprising:
- a pair of horizontally spaced apart upright side walls defining upper and lower end portions and an airtight interior space;
- a horizontally extending upper side wall having an airtight interior space and including opposite ends connected to the upper end portions of the upright side walls;
- a horizontally extending lower side wall having an airtight interior space and including opposite ends connected to the lower end portions of the upright side walls;
- porous insulating material disposed in the airtight interior spaces of the upright side walls, the upper side wall, and the lower side wall;
- wherein the upright side walls and the upper and lower side walls comprise a one piece integral tubular structure defining an insulated interior space, wherein the one piece integral tubular structure has a front perimeter extending around a front opening that provides access to the insulated interior space and wherein the airtight interior spaces of the side walls, the upper side wall, and the lower side wall have a vacuum formed therein; and
- at least one door movably connected to the one piece integral tubular structure whereby the at least one door at least partially closes off the front opening when the at least one door is in a closed position, and wherein the at least one door provides access to the insulated interior space through the front opening when the at least one door is in an open position;
- the one piece integral tubular structure has a rear perimeter extending around a rear opening; and including:
- an upright rear panel extending over the rear opening.
8. The free-standing vacuum insulated refrigerator housing structure of claim 7, wherein:
- the one piece integral tubular structure defines a rearwardly-facing surface extending around the rear opening; and
- the upright rear panel is disposed against the rearwardly-facing surface.
9. The free-standing vacuum insulated refrigerator housing structure of claim 8, wherein:
- the rearwardly-facing surface is planar.
10. The free-standing vacuum insulated refrigerator housing structure of claim 7, wherein:
- the upright rear panel includes an insulated divider that divides the insulated interior space into first and second spaces.
11. The free-standing vacuum insulated refrigerator housing structure of claim 10, wherein:
- the insulated divider extends vertically.
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Type: Grant
Filed: Jun 5, 2015
Date of Patent: Dec 5, 2017
Patent Publication Number: 20150267958
Assignee: Whirlpool Corporation (Benton Harbor, MI)
Inventors: Steven J. Kuehl (Stevensville, MI), Axel Julio Ramm (Saint Joseph, MI), Guolian Wu (Saint Joseph, MI), James W. Kendall (Mount Prospect, IL), Nihat Cur (Saint Joseph, MI), Paul B. Allard (Stevensville, MI)
Primary Examiner: Daniel Rohrhoff
Application Number: 14/731,796
International Classification: F25D 23/00 (20060101); F25D 23/06 (20060101); F25D 23/02 (20060101); F25B 39/00 (20060101); F25D 11/00 (20060101); B29C 53/00 (20060101); H04R 3/12 (20060101); B23P 15/26 (20060101); F25B 39/02 (20060101); F25C 1/00 (20060101);